Semi-automated layup process for fabrication of wind turbine blades using laser projection system

ABSTRACT

A system for fabrication of a wind turbine blade including a laser projection which identifies the dimensions for a plurality of layup segments; determines the sequence of layup segments within first and second sections of the mold, wherein the sequence of layup segments within the second section of the mold are synchronized with the layup segments within a first section of the mold. The system also includes a projection device visually depicting the boundaries of a plurality of layup segments onto the mold. This system automates fabrication of composite structures by setting a pace for each task and ensuring operators complete each task within the allotted period. The projection system and layup delivery mechanism can advance with respect the mold to ensure the pace is maintained and an overall product cycle time is adhered to.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of and claims the benefit of priorityunder 35 USC 120 to U.S. application Ser. No. 16/235,325 filed Dec. 28,2018, which claims the benefit of priority under 35 U.S.C. § 119(e) ofU.S. Provisional Application No. 62/611,803 filed Dec. 29, 2017, theentire contents of each are hereby incorporated by reference.

FIELD OF THE DISCLOSED SUBJECT MATTER

The disclosed subject matter relates to a system for manufacturingcomposite structures. Particularly, the disclosed subject matter isdirected to a system and corresponding method of manufacturing windturbine blades. Particularly, the present disclosed subject matterconverts the traditional layup process in wind blade manufacturing to asemi-automated assembly line-type process. The system disclosed hereinincludes an optical (e.g. laser) projection system, which provides theadjustment, and control, of the production pace and facilitates theimplementation of standard work as a lean manufacturing tool.

SUMMARY OF THE DISCLOSED SUBJECT MATTER

The purpose and advantages of the disclosed subject matter will be setforth in and apparent from the description that follows, as well as willbe learned by practice of the disclosed subject matter. Additionaladvantages of the disclosed subject matter will be realized and attainedby the methods and systems particularly pointed out in the writtendescription and claims hereof, as well as from the appended drawings.

To achieve these and other advantages and in accordance with the purposeof the disclosed subject matter, as embodied and broadly described, thedisclosed subject matter includes a system for fabrication of acomposite structure comprising a mold, the mold having a contouredsurface; a layup projection generator, which: defines a plurality ofmold sections; identifies the dimensions for a plurality of layupsegments; specifies the sequence of layup segments within a firstsection of the mold; and specifies the sequence of layup segments withina second section of the mold, the sequence of layup segments within thesecond section of the mold synchronized with the layup segments within afirst section of the mold. The system also includes a projection devicevisually depicting the boundaries of a plurality of layup segments ontothe mold; and a layup delivery mechanism delivering a layup segment toat least one section of the mold.

In some embodiments, the projection device simultaneously depicts theboundaries of a plurality of layup segments onto the mold. In someembodiments, the projection device sequentially depicts the boundariesof each layup segment onto the mold.

In some embodiments, a first section of the mold defines the rootportion of a wind turbine blade and a second section of the mold definesthe tip portion of a wind turbine blade.

In some embodiments, a density of layup segments in a first section ofthe mold is higher than the density of layup segments in a secondsection of the mold.

In some embodiments, the layup delivery mechanism for layup segments ofthe first section of mold is different from the layup delivery mechanismfor layup segments of the second section of the mold.

In some embodiments, the layup projection generator is disposed abovethe mold, and the layup projection generator and mold are configured forrelative movement.

In some embodiments, the projection device projects the boundaries oflayup segments via an optical laser.

The disclosed subject matter includes a method of manufacturing acomposite structure comprising: providing a mold, the mold having acontoured surface; providing a layup projection generator, with thelayup projection generator: defining a plurality of mold sections;identifying the dimensions for a plurality of layup segments; specifyingthe sequence of layup segments within a first section of the mold, thesequence of layup segments within the first section of the moldconfigured as series of sub-tasks, each sub-task having a start and end,with an endpoint of the first sub-task occurring prior to start of thenext sequential sub-task; specifying the sequence of layup segmentswithin a second section of the mold, the sequence of layup segmentswithin the second section of the mold synchronized with the layupsegments within a first section of the mold; projecting the boundariesof a plurality of layup segments onto the mold; and delivering a layupsegment to at least one section of the mold.

In some embodiments, a first section of the mold defines the rootportion of a wind turbine blade and a second section of the mold definesthe tip portion of a wind turbine blade.

In some embodiments, layup segments within the first section of the moldare projected at a faster rate than layup segments within the secondsection of the mold.

In some embodiments, each layup segment within the first section of themold includes a unique boundary projection. In some embodiments aplurality of layup segments within the second section of the mold remainprojected onto the second mold section throughout at least two sub-tasksof a sequence within the first section of the mold.

In some embodiments, sequence of layup segments are predefined timeintervals. Additionally, the cycle time for manufacturing the compositestructure can be defined based on the sequence of layup segments.

The In some embodiments, the layup projection generator is disposedabove the mold with the layup projection generator and mold configuredfor relative movement.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and are intended toprovide further explanation of the disclosed subject matter claimed.

The accompanying drawings, which are incorporated in and constitute partof this specification, are included to illustrate and provide a furtherunderstanding of the method and system of the disclosed subject matter.Together with the description, the drawings serve to explain theprinciples of the disclosed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of various aspects, features, and embodiments ofthe subject matter described herein is provided with reference to theaccompanying drawings, which are briefly described below. The drawingsare illustrative and are not necessarily drawn to scale, with somecomponents and features being exaggerated for clarity. The drawingsillustrate various aspects and features of the present subject matterand may illustrate one or more embodiment(s) or example(s) of thepresent subject matter in whole or in part.

FIG. 1 is a schematic representation of the Semi-Automated Layup Processfor Fabrication of Wind Turbine Blades using Laser Projection System inaccordance with the disclosed subject matter.

FIG. 2 is a schematic representation of an exemplary embodiment of thepresent disclosure, depicting a with various layup segments projectedwithin a wind turbine blade mold.

FIGS. 3A-C are images of a layup segment deposited within a mold with alayup label projected thereon.

FIG. 4 is an image of an exemplary layup delivery cart.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

Reference will now be made in detail to exemplary embodiments of thedisclosed subject matter, an example of which is illustrated in theaccompanying drawings. The method and corresponding steps of thedisclosed subject matter will be described in conjunction with thedetailed description of the system.

Extracting the kinetic energy of the wind and transferring it to thepower generators, blades are one of the most critical components of windturbine systems. As geometry, structural strength and weight of theblades directly impact the efficiency of the turbine system, designersare continuously attempting to excel the aerodynamic characteristics ofthe blades while increasing the length and lowering the weight of thestructure. To keep up with this dynamic design environment, fabricationmethods are necessitated to undergo tremendous continuous improvementsas well. Employing the new emerging manufacturing technologies alongwith implementation of lean manufacturing techniques, the ultimateobjectives of wind turbine blade manufacturers are improving the qualityof blades while increasing the productivity and efficiency.

An assembly line-type operation is a semi-automated process in whichsub-tasks are executed in a sequential manner to create an end product.From manufacturing to product development and even management, thismethodology is being vastly employed to increase throughput. An aspectof the disclosed subject matter is to introduce and detail a novelsystem that improves wind blade manufacturing with unique assembly linemethodology. Utilizing projection technology (e.g. 3D lasersstrategically positioned along the mold) the disclosed system convertsthe traditional fully-manual overlapping layup process into asemi-automated assembly line-type operation. As the result of thisapproach, the layup processes will transition from procedural tosequence mode where it consists of a set of tasks next to each other ina set order. The advantages of this arrangement is could be seen in awide range from quality to cycle time, productivity, communication andmaterial flow.

Manufacturing composite wind turbine blades using resin infusion methodconsists of three main steps; layup, infusion and mold closure. Theformer—layup—which happen to be the most human resource intense step hasthe most significant impact on the quality of the final product. In thisset of sub-processes, variety of different reinforcement and corematerials are placed inside the molds, prior to infusion process begins.Optimizing this step provides significant improvements in both qualityand productivity. The purpose of the current disclosed subject is tointroduce a system and corresponding method to achieve this goal.

In traditional layup process, following the work instruction procedures,production associates place the reinforcement layers in various moldlocations. In this procedural approach, the key element is to maintainthe labor balance and allocate the optimized work forces for eachsub-task. Due to the fact that production associates are underconstraint in this type of procedural operations, it is extremelychallenging to enforce the practice of standard work procedures andhence, it is difficult to trace the quality issues which makes theroot-cause analysis a tedious task. Consequently, this variabilitycreates deviations in manufacturing operations, which can compromise thestructural integrity and performance of the blade.

In accordance with an aspect of the present disclosure, the laserprojection files for all the layup patterns are generated (FIG. 1 step1). A layup pattern can consist of a single layup segment, or aplurality of layup segments which can be joined along one or moreborders/boundaries of adjacent segments. Also, the blade root sectionincludes more layup segments than the tip section, and often with a morecomplex geometry. For example, the root section often includes loadbearing components (e.g. root inserts), with a greater radius ofcurvature than layup segments of the tip section. While root sectionincludes all the major structural layers, tip elements are mainlycomposed of local reinforcement layers for lifting and positioningpurposes (FIG. 2 )

Thus, since the density of the reinforcement layers in the vicinity ofthe blade root is higher, in some embodiments of the presently disclosedsubject matter, each mold and its corresponding reinforcement materialsare divided (FIG. 1 , step 2) into two separate sections or regions;e.g., root and tip (dashed line in FIG. 2 ). An exemplary line ofdivision is shown in FIG. 2 is at approximately mid-span, thus depictingthe root section and tip section as approximately equivalent in length.However, it is to be understood that the division of first (e.g. root)and second (e.g. tip) sections can be scaled as desired, depending onthe varied complexity of each section. Also, the blade can be dividedinto any number of sections as needed to track the varying complexity oflayup segments along the blade length. In other words, the system canemploy any number of sections needed to accommodate the changing layupdensity, or gradient, along the blade span.

In accordance with another aspect of the present disclosure, layup tasksin the root section are defined with a predetermined time interval forcompletion. In some embodiments, this predetermined time interval isbased on standard work guidelines (e.g. average time for completionacross a given number of employees). Additionally or alternatively, thesystem can be trained, e.g. via a machine learning algorithm toestablish the sequence of layup projections. For example, each task canbe performed manually with the completion time recorded for each task.This can be performed numerous times and while varying parameters foreach iteration, e.g., number of operators, shift (morning vs. evening),layup material type, blade model, etc. As a result, a particularduration (e.g., mean, median, etc.) can be set as the sequence timeperiod for each layup projection. Additionally, and in conjunction withthe sequence time determination, the dimensions of each layup segment tobe positioned within the root section is identified.

In an exemplary embodiment, layup tasks in the root section aresequenced as series of closed sub-tasks where no two steps overlap witheach other (FIG. 1 step 4). Each sub-task is defined with a start pointand an end point, with an endpoint of a first sub-task occurring priorto start of the next sequential sub-task. In some instances, the endpoint of a first task can coincide with a start point for the nextsequential sub-task. An exemplary sub-task is the process of laying upeach unique piece of reinforcement layer in the root section of theblade. In contrast, sub tasks that follow each other may or may notshare identical projection within the tip section, as described infurther detail herein.

In some embodiments, the tip section layup tasks can be defined inparallel with the sequencing of tasks within the root section (FIG. 1step 3). The tip section layup tasks can be designed to take place withslower pace since the layup segments disposed within this section of themold are typically less dense, and thus less burdensome and timeconsuming to complete as compared to the root section. To optimizeefficiencies, the sequence of layup segments within the tip section ofthe mold are synchronized with the layup segments within the rootsection of the mold such that the sequence of root layup segments iscompleted at the same time the sequence of tip layup segments iscompleted. For example, in an embodiment in which there are 10projections in the root section and only 5 projections in the tipsection (wherein each task requires an equal time to complete) eachprojection in the tip section correlates with (i.e. throughout theduration of) 2 projections in the root section. In this scenario, therewill be a total of 10 subtasks (equal to the number of layupprojections) within the root section. The root section layup and tipsection layup begin and end in unison (with the root section havingundergone twice as many tasks/layups). Eventually, the entire layupprocess ends, when all the sequences in the root section layup arecompleted.

Once the sequencing tasks described above are completed (which caninclude defining: layup duration, location and order of installation),an overhead optical system is utilized to project (e.g. via laser) thelayup pattern for each step (FIG. 1 step 5). An exemplary optical systemis provided in U.S. application Ser. No. 16/023,891, the entire contentsof which are hereby incorporated by reference. In some embodiments, asingle overhead projection device can be employed to visually depict thelayup patterns along the entire blade span. In some embodiments, aplurality of overhead projection devices can be employed to visuallydepict the layup patterns with a sub-set of projection devices dedicatedto a select section. In some embodiments the subset of projectiondevices is evenly distributed about the various mold sections (e.g. 1projection device for the root section; and 1 projection device for thetip section). In other embodiments, a higher concentration of projectiondevices can be employed about the root section of the mold than the tipsection of the mold since the root section requires a more dense andcomplex layup configuration. In some embodiments, approximately 4-5projection devices are employed about the root section of the mold, andapproximately 3-4 projection devices are employed about the tip sectionof the mold. Additionally, the projection device(s) can be configuredfor relative movement (e.g. rotation and/or translation along any or allof the X, Y, Z-axes) with respect to the mold sections. Also, each layupprojection device can be configured for independent movement relative toeach other.

In accordance with an aspect of the present disclosure, a uniqueprojection file can be mapped to each layup pattern in the root section.FIG. 2 illustrates an exemplary embodiment of the present disclosure,depicting three projection files (Step i−1, Step i, and Step i+1) withinthe root section, with each layup segment (XA, XB and XC, respectively)shown to have a unique dimension/boundary. Due to the size of the rootsection, reinforcement layers are not typically laid all as one piece.Instead root section layup segments are sectioned in the chord-wisedirection (with 3 sections depicted in the illustrated embodiment: XA,XB and XC). These root sections and whether they are on the leading edgeside or trailing edge side drive the sequencing of the layup process.The red lines depict the boundary of each segment.

In contrast, a plurality of projection files share the identical layuppattern in the tip section to compensate for the lower number of layersin the tip compared to the root. FIG. 2 illustrates an exemplaryembodiment of the present disclosure, depicting three projection files(Step i−1, Step i, and Step i+1) within the tip section, with two layuppatterns, e.g. tip segment “TA” (see borders shown in Step i−1 and Stepi) shown to have a common dimension/boundary. In some embodiments, thiscommon layup pattern within the tip section repeats based on a fixednumber of intervening patterns projected. In some embodiments, thiscommon layup pattern repeats in a non-uniform manner. In the exemplaryembodiment depicted in FIG. 2 , only a single layup segment is projectedwithin the root section of the mold during any given step. Thus, onlylayup segment XA is projected during step i−1 in the root section, onlylayup segment XB is projected during step i in the root section; onlylayup segment XC is projected during step i+1 in the root section.

Conversely, the tip section can maintain a common layup projectionacross multiple steps. For instance, tip segment TA can be projectedwithin the tip section during step i−1, and this same segment TA canremain projected during step i as well. When a subsequent layup segmentis to be projected within the tip section, this subsequent layupsegment, e.g. TC, is projected in step i+1 (and the previously projectedsegment TA is removed as it is expected to have been completed).

In some embodiments the root section can have only a single layupsegment projected during any step/task; whereas the tip section can havea plurality (e.g. up to 4) projections depicted during a singlestep/task. This configuration is advantageous in that it allows for areduction in workforce allocation in this section of the mold (FIG. 2 ).The projection device changes the sequenced process to semi-automatedoperation where operators are tasked to execute the manual layup processwhile keeping up with the projection pace (FIG. 1 step 6).

Additionally or alternatively, in some embodiments the projection of thelayup patterns can be performed simultaneously (i.e. all at once), orthe patterns can be selectively and discretely projected one at a time.Additionally, when in the select pattern depiction mode, switching fromone pattern to another can be performed, e.g., by a remote controller.

Furthermore, the presently disclosed system includes a layup deliverymechanism for delivering each layup segment to the mold. In someembodiments, a plurality of layup segments are delivered to the mold inbulk, whereas other embodiments deliver the layup segment on anas-needed or just-in-time schedule. In some embodiments a plurality oflayup delivery mechanisms (e.g. conveyor systems) can be employed, withone dedicated for the tip section and one dedicated for the rootsection. The layup delivery mechanisms can be configured to move withrespect to the blade mold, e.g. parallel to the blade span.Additionally, in some embodiments the layup delivery mechanism cantraverse the blade in a chord-wise direction to facilitate dispensing ofthe layup segment directly into its designated/projected position withinthe mold.

FIGS. 3-4 depict an exemplary layup delivery mechanism, configured as amoveable cart 100 in FIG. 4 . The layup delivery mechanism 100 includesa plurality of discrete holders, each designated to hold and dispense asupply (10, 20, etc.) of a specific layup material. The spindles (10,20, etc.), of layup material can be distinguished based on a variety ofparameters, e.g. material type, thickness of ply, spindle length, etc.Each holder is labeled with an identification code that corresponds to alayup projection label that is illuminated/depicted within the moldduring the layup process.

For example, FIG. 3A depicts a layup projection within the root sectionof a mold in which the ply the identification code “6AB” is projectedonto the mold (along with the boundaries/borders of that layup segment,shown in pink). This identification code “6AB” signals to the operatorwhich holder of the layup delivery mechanism 100 includes theappropriate spindle of layup material is to be applied during thissequence. In use, the operator looks for the matching spindle label“6AB” on the layup delivery mechanism 100, obtains the desired layupsegment, and then installs it into the mold such that the physicalboundaries/borders of that layup segment match the projected boundaries(within the time frame allotted by the sequence projection).

Next, as shown in FIG. 3B, the operator observes the layup projectionwithin the root section of a mold in which the ply the identificationcode “7A” is projected onto the mold (along with the boundaries/bordersof that layup segment, shown in green). Similarly, the operator looksfor the matching spindle label “7A” on the layup delivery mechanism 100,obtains the desired layup segment, and then installs it into the moldsuch that the physical boundaries/borders of that layup segment matchthe projected boundaries (within the time frame allotted by the sequenceprojection).

FIG. 3C, depicts an exemplary layup projection within the tip section ofa mold in which the identification code “L 3B” is projected onto themold (along with the boundaries/borders of that layup segment, shown inpink). Again, the operator would locate the similarly codified supply oflayup material and select the appropriate size for installation into themold such that the physical boundaries/borders of that layup segmentmatch the projected boundaries (within the time frame allotted by thesequence projection).

As shown in FIG. 4 , the layup delivery mechanism 100 can include atable of identification codes including numerous designation schemes(e.g. a prefix such as “L” can indicate Lower Mold, numbers—to indicatesequence order and/or location within the mold; colors—to conveyadditional information to the operator such as material type, relativecomplexity or sequence time interval, etc.).

In the current disclosed subject matter, the projectiondevice/controller is equipped to automatically change the projectionfiles following a pre-defined time interval scheme. These time slots areestimated based on the practice of the standard work for each processstep (and in some embodiments can include a productivity time marginthat is a function of parameters, e.g., the number of production teammembers, work shift and production team skill level). Using this margin,various cycle time patterns can be enforced in the production floor byprojecting the layup patterns for the appropriate/sufficient time forthe operator to complete installation of that layup segment, and thenadvancing to the next layup projection thereby ensuring the operatormaintains the pace to adhere to the forecasted aggregate cycle time. Atthe end of the layup process, the total cycle time would be equal to thesum of all laser projection time intervals. Accordingly, the presentdisclosure allows for manufacturers to accurately forecast the totalcycle time for blade layup, with certainty, and in advance of the startof the operation.

Automated projection of sequenced layup patterns not only sets the cycletime for production but also enforces the practice of standard work asit does not leave any room or degrees of freedom for the operators toswitch the process steps or change the sequence order. This is a keyelement in achieving the consistency in manufacturing and to maximizethe traceability which is critical for improving the quality of theblades.

In accordance with another aspect of the disclosure, in some embodimentsa procedure can be incorporated for the case where production fallsbehind and fails to keep up with the automated projection pace (FIG. 1step 7). This could be due to issues such as productivity problems orunexpected material quality issues. To cope with this situation, analert system can be provided to the supervisor. In some embodiments,once activated, this signal stops the automatic projection immediatelyand the issue will be brought to the attention of the productionsupervisors. Once the issue is resolved, the projection can go back tomatch the ongoing sub-step and the automatic process is resumed.

In this regard, additional guidance can be provided to the operator toalert them of the impending risk of activating the alarm. For example,the layup patterns can be depicted with a visual cue (e.g. blinking,with increased frequency) to signal to the operator that the allottedtime interval for that particular layup pattern is about to expire.Additionally or alternatively, select layup patterns can be outlinedwith a color-coded pattern at the outset to alert the operator that thisparticular layup pattern is afforded more/less time, has increasedcomplexity, or requires some special action by the operator.

Therefore, and in accordance with the disclosed subject matter, thesemi-automated layup process disclosed herein improves productivity andefficiency in production of molded composites, such as wind turbineblades (though it is to be understood the disclosed system and methodcan be employed for any molded composite structure). Further, thedisclosed optimization method allows for enforcement of standard workprocedures while facilitating the communication and material flow on themanufacturing floor.

While the disclosed subject matter is described herein in terms ofcertain preferred embodiments, those skilled in the art will recognizethat various modifications and improvements may be made to the disclosedsubject matter without departing from the scope thereof. Thus, it isintended that the disclosed subject matter include modifications andvariations that are within the scope of the appended claims and theirequivalents.

Moreover, although individual features of one embodiment of thedisclosed subject matter may be discussed herein or shown in thedrawings of the one embodiment and not in other embodiments, it shouldbe apparent that individual features of one embodiment may be combinedwith one or more features of another embodiment or features from aplurality of embodiments.

The invention claimed is:
 1. A system for fabrication of a compositewind turbine blade comprising: a mold, the mold having a contouredsurface; a layup projection generator, the layup projection generator:defines a plurality of mold sections; identifies the dimensions for aplurality of layup segments; specifies the sequence of layup segmentswithin a first section of the mold; specifies the sequence of layupsegments within a second section of the mold, the sequence of layupsegments within the second section of the mold synchronized with thelayup segments within a first section of the mold; a projection device,the projection device visually depicting the boundaries of a pluralityof layup segments onto the mold.
 2. The system of claim 1, wherein theprojection device simultaneously depicts the boundaries of a pluralityof layup segments onto the mold.
 3. The system of claim 1, wherein theprojection device sequentially depicts the boundaries of each layupsegment onto the mold.
 4. The system of claim 1, wherein a first sectionof the mold defines the root portion of a wind turbine blade.
 5. Thesystem of claim 1, wherein a second section of the mold defines the tipportion of a wind turbine blade.
 6. The system of claim 1, wherein thelayup projection generator is disposed above the mold.
 7. The system ofclaim 1, wherein the layup projection generator and mold are configuredfor relative movement.
 8. The system of claim 1, wherein the sequence oflayup segments projected in the second section of the mold occur at aslower pace than the layup segments projected in the first section ofthe mold.
 9. The system of claim 1, further comprising a layup deliverymechanism, the layup delivery mechanism delivering a layup segment to atleast one section of the mold.
 10. The system of claim 9, wherein thelayup delivery mechanism is configured to move with respect to the mold.11. The system of claim 9, wherein the layup delivery mechanism isconfigured to move parallel with respect to the mold.
 12. A method ofmanufacturing a composite wind turbine blade comprising: providing amold, the mold having a contoured surface; providing a layup projectiongenerator, the layup projection generator: defining a plurality of moldsections; identifying the dimensions for a plurality of layup segments;specifying the sequence of layup segments within a first section of themold, the sequence of layup segments within the first section of themold configured as series of sub-tasks, each sub-task having a start andend, with an endpoint of the first sub-task coinciding with the start ofthe next sequential sub-task; specifying the sequence of layup segmentswithin a second section of the mold, the sequence of layup segmentswithin the second section of the mold synchronized with the layupsegments within a first section of the mold; projecting the boundariesof a plurality of layup segments onto the mold.
 13. The method of claim12, wherein a density of layup segments in a first section of the moldis higher than the density of layup segments in a second section of themold.
 14. The method of claim 12, further comprising delivering a layupsegment to at least one section of the mold.
 15. The method of claim 12,wherein a first section of the mold defines the root portion of a windturbine blade, and a second section of the mold defines the tip portionof a wind turbine blade.
 16. The method of claim 12, wherein a pluralityof segments are simultaneously projected in the second section of themold.
 17. The method of claim 12, wherein layup segments within thefirst section of the mold are projected at a faster rate than layupsegments within the second section of the mold.
 18. The method of claim12, wherein each layup segment within the first section of the moldincludes a unique boundary projection.
 19. The method of claim 12,wherein a plurality of layup segments within the second section of themold remain projected onto the second mold section throughout at leasttwo sub-tasks of a sequence within the first section of the mold. 20.The method of claim 12, wherein the sequence of layup segments arepredefined time intervals.